Generator Rotor Decoupling for Gearbox Maintenance Alignment
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Solution Overview
Problem
In wind power plants with structurally integrated transmission and generator, maintenance is complicated due to the need to decouple the generator from the output shaft while ensuring precise angular positioning, which is not efficiently addressed by existing methods.
Innovation Solution
A non-rotatable connection between the generator rotor and the output shaft, supported by an assembly bearing that allows relative rotation for maintenance, using screw flanges and axial displacement, enabling easy release and alignment for maintenance positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the generator rotor is firmly fastened to the output shaft for operational integrity, then the transmission reliability is improved, but the maintenance accessibility deteriorates
Solution Approach 1:
The connection between the generator rotor and output shaft is segmented into two distinct states: a firmly fastened state for operation using keyway and set screws, and a decoupled state for maintenance. The keyway provides a permanent structural connection while the set screws allow for controlled disassembly, enabling the system to transition between reliable operation and accessible maintenance modes.
Solution Approach 2:
The connection system transitions from a static firmly fastened state to a dynamic state where the generator rotor can be decoupled. The set screws and keyway arrangement allow the connection to be dynamically adjusted between tightened (operational) and loosened (maintenance) states, providing flexibility without compromising structural integrity during operation.
2Ease of repair
If the generator rotor is decoupled from the output shaft for maintenance, then the maintenance accessibility is improved, but the operational integrity deteriorates
Solution Approach 1:
The keyway is pre-formed in both the output shaft and generator rotor before assembly, establishing a predetermined alignment path. This preliminary structural feature ensures that when the set screws are tightened, the generator rotor automatically returns to its correct angular position, preserving operational integrity without requiring complex alignment procedures during reassembly.
Solution Approach 2:
The complex mechanical alignment process is replaced by a simpler screw-fastening system with a keyway. Instead of requiring precise manual alignment of multiple components, the keyway provides a mechanical guide that automatically ensures correct positioning when the set screws are tightened, maintaining operational integrity through a simplified mechanical means.
3Manufacturing precision
If the generator rotor is brought into a defined angular position for fastening, then the assembly precision is improved, but the assembly complexity increases
Solution Approach 1:
The keyway structure performs the alignment function automatically during assembly. When the generator rotor is inserted onto the output shaft, the keyway geometry self-guides the components into the correct angular position relative to each other. This self-aligning mechanism eliminates the need for external alignment tools or complex positioning procedures, achieving high assembly precision through the component's own structural features.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies maintenance by allowing the generator rotor to be freely rotated and axially displaced relative to the output shaft, facilitating efficient decoupling and reconnection for maintenance without compromising operational integrity.
Implementation Method 1
an assembly bearing supports the generator rotor in the output shaft
Data Source
AI summary
An arrangement including a transmission and a generator is disclosed. The generator includes a generator rotor being non-rotatably connected to an output shaft of the transmission or configured to be connectable to the output shaft of the transmission. An assembly bearing that supports the generator rotor in the output shaft is also disclosed.